US9733193B2 - Measurement of industrial products manufactured by extrusion techniques - Google Patents
Measurement of industrial products manufactured by extrusion techniques Download PDFInfo
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- US9733193B2 US9733193B2 US14/656,106 US201514656106A US9733193B2 US 9733193 B2 US9733193 B2 US 9733193B2 US 201514656106 A US201514656106 A US 201514656106A US 9733193 B2 US9733193 B2 US 9733193B2
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- 238000005259 measurement Methods 0.000 title claims abstract description 33
- 238000001125 extrusion Methods 0.000 title claims abstract description 17
- 238000000034 method Methods 0.000 title abstract description 17
- 230000005855 radiation Effects 0.000 claims abstract description 46
- 238000004458 analytical method Methods 0.000 claims abstract description 18
- 238000012937 correction Methods 0.000 claims abstract description 16
- 238000003384 imaging method Methods 0.000 claims abstract description 15
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Images
Classifications
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/86—Investigating moving sheets
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/02—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
- G01B11/04—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness specially adapted for measuring length or width of objects while moving
- G01B11/046—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness specially adapted for measuring length or width of objects while moving for measuring width
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/02—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
- G01B11/06—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material
- G01B11/0616—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material of coating
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/02—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
- G01B11/06—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material
- G01B11/0691—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material of objects while moving
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/08—Measuring arrangements characterised by the use of optical techniques for measuring diameters
- G01B11/10—Measuring arrangements characterised by the use of optical techniques for measuring diameters of objects while moving
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
- G01B11/2433—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures for measuring outlines by shadow casting
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/17—Systems in which incident light is modified in accordance with the properties of the material investigated
- G01N21/25—Colour; Spectral properties, i.e. comparison of effect of material on the light at two or more different wavelengths or wavelength bands
- G01N21/31—Investigating relative effect of material at wavelengths characteristic of specific elements or molecules, e.g. atomic absorption spectrometry
- G01N21/35—Investigating relative effect of material at wavelengths characteristic of specific elements or molecules, e.g. atomic absorption spectrometry using infrared light
- G01N21/3581—Investigating relative effect of material at wavelengths characteristic of specific elements or molecules, e.g. atomic absorption spectrometry using infrared light using far infrared light; using Terahertz radiation
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
- G01N21/88—Investigating the presence of flaws or contamination
- G01N21/95—Investigating the presence of flaws or contamination characterised by the material or shape of the object to be examined
- G01N21/952—Inspecting the exterior surface of cylindrical bodies or wires
Definitions
- the present invention relates to the non-contact measurement of the dimensional properties of elongated linearly extruded products such as rubber or plastic tubing, pipes and electrical cables with metallic conductor cores coated with a non-metallic insulating extruded material. It also relates to the measurement of manufactured flat products, such as rubber or plastic sheets, insulating tape, films, paper and the like.
- Linearly extruded products of the type referred to above are usually manufactured in an extrusion line typically comprising a pay-off device, an extrusion machine, a cooling section and a take-up device for the completed product.
- radioactive beta or x-rays enables the measurement of the wall thickness of an extruded product without contact with it. These methods, however, require special handling by reason of the fact that they involve inherent health hazards as will be readily appreciated.
- the invention may also be used in the industrial field of manufacturing flat products, such as, rubber or plastic sheets, insulating tapes, films, paper and the like, thereby to measure the thickness of the material and the overall width of the product being manufactured.
- Prior art available in measuring flat products includes indirect contact methods, whereby two wheels or rollers are placed above and below the product, and the difference of the readings shown by the two wheels, indicates product thickness.
- a non-contact optical method has also been used, in which, two “distance measuring devices” are mounted above and below the product. The difference between the two distance readings indicates product thickness.
- a further limitation of the “contact” and “optical” methods is that they measure, only the thickness along a narrow part of the product width and not the complete area of the flat product sheet.
- the present invention makes use of terahertz radiation (hereinafter referred to as THz radiation) to irradiate the product as it passes through the rays on its path of travel and to utilize in a time related manner the radiation after passing through the product to determine its dimensional profile.
- THz radiation terahertz radiation
- the frequencies of THz radiation are located between infra-red and micro-waves and the wavelengths of THz radiation are in the range between 30 micrometers and 3 millimeters.
- Terahertz radiation has the advantage in that it behaves in a manner similar to that of white light, that is to say that the radiation can be reflected by mirrored surfaces but is able to penetrate and pass through dielectric or insulating materials such as rubber, paper and various plastics including polyethylene and the like.
- the speed of transmission of THz radiation through the dielectric or insulating material is dependent on the chemical composition and material density of the product and this property and a penetrative ability of the THz radiation through dielectric or insulated materials will be used to obtain the measurements required.
- the system disclosed herein utilizes an optical system to produce a curtain of THz radiation through which the product passes in a linear fashion in its path of travel.
- the transient time or speed of each successive ray in the curtain of rays is used to compute, by matrix imaging methods, the dimensional parameters of the product in particular to determine the thickness of the extrusion coating so as to ensure that the coating thickness meets operational requirements.
- Uniformity of the transient times or speeds of the rays through the extruded coating are important in achieving high accuracy of the results of the measuring process.
- an apparatus for measuring by non-contact, the dimensional parameters of an elongated, non-guided industrial product such as a rubber or plastic tube or electrical cable, being extruded continuously in free space comprising a terahertz radiation unit, a rotating mirror for scanning terahertz rays emitted from a point source across a first lens to produce a curtain of parallel terahertz rays, through which the product travels linearly at right angles thereto, the rays after passing through the insulating material being collected by a second lens, and focused at a terahertz sensor, an image analyser operatively associated with the sensor for performing time related imaging analysis of terahertz rays penetrating the insulating material to provide a matrix image from which to determine the dimensional parameters of the product characterised in that the analyser incorporates a processor for computing correction data representative of variation in the transit times between the rays crossing the product, the processor being adapted to provide time related correction signals
- FIG. 1 is a side view of an extrusion line for manufacturing an electrical cable
- FIG. 2 shows a side view of a double or triple extrusion line for coating the inner metallic core of an electrical cable
- FIG. 3 illustrates the application of the invention to a tube pipe or electrical cable being extruded in a linear direction along their axes of travel;
- FIG. 4 shows a different view of the arrangement shown in FIG. 3 wherein the travelling product is shown in cross-section to better illustrate how the parallel rays of THz radiation are produced from a single THz radiation source;
- FIG. 5 illustrates in schematic view an extruded product in its path of travel and being subject to measurements by means of THz radiation in accordance with the invention
- FIG. 6 shows the matrix image of the cross-section of an extruded tube or pipe and in graphical form the results of the measurement of its wall thickness according to an embodiment of the invention
- FIG. 9 illustrates a device for obtaining a multiplicity of measurements of the travelling extruded product in accordance with the invention.
- FIG. 11 shows a side view of a plastic extruder similar to the extruder shown in FIG. 1 modified to extrude flat products;
- FIG. 13B illustrates the arrangement of FIG. 13A modified to cater for scanning wide products and provided with a reciprocating motion to achieve that end;
- FIG. 14 shows the cross-section of a product under test together with an associated matrix in graphical format thereby to enable the imaging analysis of the product and provide a measure of its width;
- FIG. 15 shows in graphical display the resulting analysis of the emitted Terahertz radiation (THz) from the product to provide evidence of ridges or fissures in the manufactured product;
- THz Terahertz radiation
- FIG. 16 shows the results of imaging analysis to display contaminants in the finished product such as iron filings or sand particles and the like.
- FIGS. 17 and 18 are views based on the arrangement shown in FIG. 4 to illustrate how measurement inaccuracies occur as a result of axial movement of a travelling product in its path of travel through a curtain of parallel rays of THz radiation.
- FIGS. 1-16 Preferred embodiments of the invention are shown in FIGS. 1-16 to which reference will be made to the following discussion.
- this illustrates an electrical cable extrusion line comprising a payoff 1 extruding a metallic conductor 2 made of copper, aluminum or steel into an extruder 3 .
- Rubber or plastic material is introduced into a hopper 4 in the cold state, heated in the extruder 3 which extrudes resulting hot plastics onto the metallic conductor 2 through a forming die-head 5 .
- the insulated cable is thereafter hauled through a water cooling section 6 and wound on take-up 7 .
- a non-metallic pipe or tube extrusion line is similar in many respects to a cable line but in which a payoff 1 is not required as the tube or pipe will be formed inside the extruder 3 .
- Measurement of cable parameters such as diameter/wall thickness and/or eccentricity will take place at positions either before or after the water cooling section 6 .
- FIG. 2 there is shown a double or triple extruder line 3 . 1 , 3 . 2 in which two or three extrusions take place in series and at the same time.
- extrusion lines manufacture electric cables for special applications such as for use in under sea water communications or high voltage transmission cables.
- the cable is extruded in a catenary tube 8 in which the cable installation is heat cured in a steam or nitrogen atmosphere, before it exits into the water cooling section 6 and take-up 7 .
- FIG. 3 a product 10 , which, in embodiments, is a tube, pipe or electric cable, is shown being extruded in a linear direction along the axis of the product as shown by arrow 11 .
- a Terahertz (THz) radiating unit 12 provides a ray 13 directed onto a reflecting surface.
- the reflecting surface is either a single-sided mirror, or one facet of a polygonal mirror drum driven in a rotating manner 14 by means of an electric motor 16 , creating a rotating mirror 15 .
- This rotation in effect scans the ray 13 across the diameter of a lens 17 which produces a curtain of parallel scans of rays across the product 10 .
- a lens 18 is positioned on the opposite side of the product 10 to receive the THz rays from the lens 17 .
- FIG. 4 is a cross-sectional view through the product 10 of FIG. 3 , to better illustrate the passage of the THz radiation from the unit 12 to rotating mirror 15 the lenses 17 , 18 and the THz sensor 19 .
- this method is useful as firstly the product does not have to be guided by contact rollers and secondly, it is important in an application where the object is in a hot state, rendering the same, difficult to guide in any manner or form.
- FIG. 5 shows the product 10 in a position between a transmitter 20 of THz radiation and a receiver 21 , mounted on a cradle base 22 .
- the transmitter 20 houses a THz radiation unit, the motor-driven scanning mirror drum device, i.e. a rotating mirror 15 , and lens 17 shown in previous figures, thereby to produce a parallel curtain of THz rays across the space between transmitter 20 and receiver 21 .
- the motor-driven scanning mirror drum device i.e. a rotating mirror 15
- lens 17 shown in previous figures
- the receiver 21 houses the lens 18 , THz sensor 19 and the THz imaging analysis unit circuit, determining the “transit time” of each successive THz ray through the insulating part of the product 10 under test and outputs the values on a processing unit 23 (shown in FIG. 10 ) which is connected to receiver 21 , either by wire or wireless connection.
- the processing unit 23 computes the imaging analysis information and produces matrix images and values of overall diameter (D) inner diameter (d) and eccentricity (E) of the product under test, as shown in FIG. 10 .
- FIG. 6 the results of measurement of the cross-section of a tube under test is shown in which (D) is the overall diameter (d) is the inner diameter.
- the horizontal X-axis of the graph displays the “transit times” of the THz radiation t 1 , t 2 , t 3 and the vertical Y-axis of the graph represents the scanning time T.
- the wall thickness of the tube is denoted by W 1 and W 2 in the vertical axis and the average thickness may be computed from the formula (W 1 +W 2 )/2.
- FIG. 7 shows similar results to those shown in FIG. 6 but wherein the cross-section is of a cable in which t 1 and t 2 are the “transit times” along the x-axis of the graphical representation shown and the scanning rate T in the vertical y-axis.
- (D) represents the overall diameter of the cable and (d) represents the electrical conductor diameter (core) of the cable under test.
- FIG. 9 shows an arrangement wherein the transmitter 20 of THz radiation and the receiver 21 for the radiation after passing through product 10 may be mounted on a rotatable cradle base 22 , (see FIG. 5 ) which is able to perform the following functions.
- the cradle base 22 is able to oscillate about the center of the travelling product 10 in a “to and fro” rotation and also in a continuous circular mode, illustrated by the arrows 24 , 25 .
- Non-contact transmission from a controller (not shown) to the imaging analysis circuit provided in the receiver 21 permits communication of all functions that are being operated in the receiver 21 as well as the transmitter 20 .
- the invention as described in the preceding embodiments thereof, is able to apply control functions to extrusion lines, whereby by measuring the diameter deviations, feedback can be applied to make adjustments to the extrusion line production speed, in order to maintain the diameter of the cable or tube within required specifications.
- the extruder output may also be used for the same purpose.
- the cable eccentricity may be corrected as referred to already by adjustments to the forming die-head 5 , of the extruder 3 .
- FIGS. 11-16 Further preferred embodiments of the invention are shown in FIGS. 11-16 .
- FIG. 11 shows a side view of a plastic extruder 26 similar in operation to the extruder ( 3 ) in FIG. 1 but having a modified forming die-head 27 , designed to extrude flat sheets of rubber or plastic materials including, polyethylene, nylon, PVC, acrylic and the like, in varying thicknesses and widths.
- the hot material exiting from forming die-head 27 enters a cooling zone 28 , comprising a number of cooling rolls or calendars, which also determine the thickness of the sheet.
- the width of the sheet is determined by “side slitters” not shown.
- the sheet progresses to the take-up 29 and measurements of thickness and width, as well as quality control, may take place in position 30 .
- FIG. 12 shows a “paper sheet producing line” whereby, paper exits from the Pulping Machine (not shown) and enters a drying zone 31 made up from heated drums. Next, the paper moves on to a coating zone 32 thereby it may be coated with various chemicals or plastic materials, depending on application requirements.
- the paper is “thickness sized” by pressure rollers and the width is determined by “edge slitters” (not shown).
- the finished paper sheet is wound on to a drum 33 and measurements of thickness and width and quality control, may take place in position 34 .
- FIG. 13A shows an “installation,” comprising a transmitter 20 and receiver 21 (shown in FIG. 5 ) mounted on a C-Frame 35 , whereby the curtain of parallel rays of said THz radiation (page 3, lines 9-11) thereof, is scanning continuously the complete surface area of a flat product 37 , in its path of travel 38 .
- the span of the curtain of parallel rays of said THz radiation is adequately wide, thereby to cope with the full width of product 37 .
- FIG. 13B it is possible to mount additional said “installations” (which comprise a receiver 21 and transmitter 20 as shown in FIG. 5 ) on the C-frame (not shown), thereby, to provide, said complete scanning coverage, to the full width of the said product 37 under manufacture, on a continuous basis.
- Single or multiple “installations” (which comprise a receiver 21 and transmitter 20 as shown in FIG. 5 ), are connected to the processing unit 23 ( FIG. 10 ), either by wire or preferably by wireless communication, thereby measurements of said product thickness and dimensional parameters of the flat sheet as well as quality control inspection results, are determined by imaging analysis and displayed in a matrix.
- the processing unit 23 ( FIG. 10 ), can provide complete Data Logging of several lengths of products, as may be required in cases where high quality is necessary, in the performance and application of said product.
- FIG. 14 shows a cross section of product 39 under test, together with the associated matrix in a graph format, whereby the thickness is represented by (t) in the x-axis and the width is represented by (w) in the y-axis, in a similar manner to the matrix shown in FIG. 6 .
- FIG. 15 shows a product 40 with defects. The resulting analysis of the time related signals are displayed in the associated matrix thereof, the x-axis shows ridges as (t 2 ), fissures as (t 3 ) and (t 1 ) as the product thickness.
- FIG. 16 shows contaminants in the product, including iron filings or sand particles and the like, displayed as dots in the associated Matrix.
- FIG. 17 is an illustration in side view of the scanning section of the optical measuring system shown in FIG. 4 .
- the lens 17 is of the plano-convex type, with A A 1 being the diameter and B C the focal length of the lens 17 .
- Each successive ray 13 rotating in direction 14 , comes in contact with the lens 17 at point A, whereby the lens 17 effectively “bends” the rays 13 , from a rotating mode to a linear mode, thus forming a curtain of THz rays, parallel to the centerline 41 .
- FIG. 18 shows the optical measuring system of FIG. 4 further illustrating the principle of measuring the dimensional parameters of the product 10 and the reasons why inaccuracies in dimensional measurement occur due to axial movement of the product in its path of travel.
- Each successive ray 13 travelling across the diameter A A 1 of the lens 17 at speed (V), will take a transit time (t 4 ) crossing the product 10 from edge to edge.
- the non-linear scanning speed (V) of the rays 13 travelling across the product 10 produces varying transit time periods (t 4 ) being measured over the product 10 , depending on the position of the product 10 , within the curtain of parallel THz rays 13 , and therefore inaccurate parameter measurements for the product 10 .
- the speed of the ray 13 VA is faster at the (edge) A of lens 17 , than speed VB at the (center) B of lens 17 .
- the product 10 If the product 10 is positioned near the middle B of the lens 17 , it will appear to be larger, as the transit time (t 4 ) across the product 10 will be longer.
- the polynomial (P) calculates, by software, the values of (e), (f) and (g) and determines a correction value (F) which is a function ( ⁇ ) of (P).
- ( F ) f ( P )( e,f,g,h )
- Lens 18 receives the THz rays 13 and focuses the rays on to sensor 19 and imaging analysis unit referred to hereinbefore with reference to FIG. 3 , whereby the polynomial (P) is used to apply within the processing capability of the analyzer unit a continuous stream of correction data to the software of the analyzer unit thereby creating a correction value (F), for every successive ray 13 , thus eliminating all instantaneous optical and positional errors of the product 10 , travelling linearly anywhere within the curtain of THz rays.
- P polynomial
- the present invention is particularly suitable in dimensional applications in the range of 80-150 microns, such as optical fibers, fine wires and the like, and also in close tolerance data transmission cables, LAN, CAT 6 & 7 and CATV, as well as in the manufacture of High Voltage Power cables.
- the advantage of the present invention is further shown in flat product applications such as plastic sheets, tapes, films, paper production and the like FIG. 11 and FIG. 12 , whereby the curtain of THz rays, in which all rays are individually of 1 micron accuracy, perform correct measurements of the flat sheet width.
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Abstract
Description
E=S/(D/2−d/2)×100%
Angle(a)=tan−1(AB/BC)=tan−1(15/80)=10.6°Degrees
V=d/d(a)(tan(a)=1/cos2(a)
(VA)=1/cos2(10.6°)=1.035
(VB)=1/cos2(0°)=1/(1)2=1.00
VA−VB=1.035−1.000=+0.035
-
- (e): The angle (a) between BC and AC of the triangle ABC;
- (f): The location of the
product 10 within the curtain of THz rays 13 - (g): The transit time period (t4) of each
successive ray 13 travelling across theproduct 10 - (h): The physical parameters of
lens 17
Thus, (F)=f(P)(e,f,g,h)
-
- (i) Speed of
ray 13 at point A (edge) oflens 17, VA=1.035 Correction to be applied (F)=0.035 therefore corrected speed is:
VA=1,035−0.035=1 - (ii) Speed of
ray 13 at point B (center) oflens 17, VB=1 Correction to be applied (F)=0, therefore corrected speed is:
VB=1−0=1 - Hence VA=VB
- Also, as pointed out earlier, due to the symmetrical disposure of lens 17:
VA=VB=VA1 - (iii) Appropriate corrections (F) are applied to the scanning speed V of
successive rays 13, ensuring that said speed V remains linear, as therays 13, travel across the diameter A, A1 of thelens 17.
- (i) Speed of
Claims (10)
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US14/656,106 US9733193B2 (en) | 2015-03-12 | 2015-03-12 | Measurement of industrial products manufactured by extrusion techniques |
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US14/656,106 US9733193B2 (en) | 2015-03-12 | 2015-03-12 | Measurement of industrial products manufactured by extrusion techniques |
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US20160265901A1 US20160265901A1 (en) | 2016-09-15 |
US9733193B2 true US9733193B2 (en) | 2017-08-15 |
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